Bajaj Discover 110 User manual

Description
1. Technical Specifications 1
2. Identification Data 4
3. Location of Parts 5
4. Steering cum Ignition lock 7
5. Petrol Tank Cap / Fuel Tap 8
6. Speedometer Details 9
7. Control Switches 10
8. Removal & Fitment of Side Covers 12
9. Removal & Fitment of Seat 14
10. Battery / Tool kit 15
11. How to ride your Bike 16
12. Safe Riding Tips 20
13. Engine Oil 22
14. Wheels - Tyre 23
15. Periodic Maintenance Information 24
26
16. Periodic Maintenance & Lubrication Chart
17. Non Use Maintenance 30
Table of Contents
Notice:
The description and illustration in this booklet
are not to be taken as binding on the
manufacturers. The essential features of the
type described and illustrated herein remaining
unaltered. Bajaj Auto Limited reserves the right
to carry out at any moment without being
obliged to bring this booklet upto-date & to do
modifications on the vehicle, parts or
accessories as may be convenient and
necessary.
Safety and Warning information :
Caution : This indicates a potential
hazard that could result in vehicle
damage. Follow the advice provided with
caution.
Warning : This indicates that a potential
hazard or injury to you or other persons
& to the vehicle can happen if advice
provided is not followed.

Engine 4 stroke, Air cooled,
Single Cylinder, DTSi
Bore x Stroke 50 mm x 58.8 mm 52 mm x 58.6 mm
Displacement 115.45 cc 124.45 cc
Idling Speed 1400 + 200 rpm 1400 + 100 rpm
Max. Net Power 8.6 PS @ 7000 rpm 11 PS @ 7500 rpm
Max. Net Torque 9.81 Nm @ 5000 rpm 11 Nm @ 5500 rpm
Ignition System DC, CDI DC, CDI
Starting Aid Kick / Self Kick / Self
Spark Plug Champion PRZ9HC & Champion PRZ9HC &
(2 Nos.) BOSCH UR4AC BOSCH UR4AC
Spark Plug Gap 0.7 to 0.8 mm 0.7 to 0.8 mm
Transmission 4 speed (Gear shifting-All Up) 1 Down 4 Up
Front Brake Drum Drum Brake / Disc Brake
Rear Brake Drum Drum
Technical Specifications
Discover 110 Discover 125
1
4 stroke, Air cooled,
Single Cylinder, DTSi

Fuel Tank Capacity
Full
Reserve
Usable Reserve
8 liters
2.3 liters
1.5 liters
8 liters
2.3 liters
1.5 liters
Dimensions
Length
Width
Height
Wheel Base
Ground Clearance
2035 mm
760 mm
1085 mm
1305 mm
165 mm
2035 mm
760 mm
1085 mm
1305 mm
165 mm
Tyre Size
Front
Rear
2.75 x 17, 41 P
3.00 x 17, 50 P
2.75 x 17, 41 P
3.00 x 17, 50 P (Drum Brake)
100/90-17 x 17, 55 P
(For Front Disc Brake version)
Tyre Pressure
Front
Rear (Solo)
Rear (with Pillion)
2
1.75 Kg/cm (25 PSI)
2
2.00 Kg/cm (28.5 PSI)
2
2.25 Kg/cm (32 PSI)
2
1.75 Kg/cm (25 PSI)
2
2.00 Kg/cm (28.5 PSI)
2
2.25 Kg/cm (32 PSI)
Discover 110 Discover 125
Technical Specifications
2

Electrical System 12V DC 12V DC
Battery 12V 5Ah MF Type 12V 5Ah MF Type
Head Lamp 12V, 35/35W Blue Tinge 12V, 35/35 W Blue Tinge
Position Lamp DRL - 0.4W DRL - 0.4W
Neutral LED LED
Tail / Stop Lamp 5/21W Bulb 5/21W Bulb
Turn Signal Indicator LED LED
Side Indicator Lamp 12V, 10W (4 nos.) 12V, 10W (4 nos.)
Hi Beam Indicator LED LED
Speedo Lamp LCD LCD
Horn 12V DC, 2A 12V DC, 2A
Low Battery Indicator LED LED
Rear No. Plate Lamp 12V, 3W 12V, 3 W
Vehicle Kerb Weight 117.5 Kg 121 Kg (Drum Brake)
122 Kg (Disc Brake)
Gross Vehicle Weight 247.5 Kg 251 Kg (Drum Brake)
252 Kg (Disc Brake)
Discover 110 Discover 125
Note :
• All dimensions are under UNLADEN condition.
• Above information is subject to change without any notice.
Technical Specifications
3

The Frame and Engine serial numbers are used to register the motorcycle. They are the unique
alpha-numeric codes to identify your particular vehicle from others of the same model and type.
Frame Number Location
On LH Side of Steering Tube
(Alpha-Numeric - 17 Digits)
Engine Number Location
On LH Side Crankcase Near Gear
Change Lever (Alpha-Numeric - 11 Digits)
Identification Data
4

Front Fork
Clutch Lever
Fuel Tank Cap
Gear Change
Lever
Speedometer
Tail
Lamp
Grab Handle
Fuel Cock
Pillion
Foot Rest
Side Stand
Location of Parts
5

This photograph is of Discover 125 m/c.
Front
Fork
Headlamp
with DRL
Nitrox Rear
Shock Absorber Carburettor with
Manual choke
Brake Pedal
Engine Oil
Inspection Window
EVAP
Fuel Tank
compatible
Rider
Foot Rest
Pillion Foot Rest
Rear
Number
Plate
Silencer
Front Brake
Lever
Mirrors
Location of Parts
6

Steering cum Ignition Lock :
It has three positions.
LOCK : Steering locked. Ignition OFF.
OFF : Steering unlock. Ignition OFF.
ON : Steering unlock. Ignition ON.
Steering Cum Ignition Lock
7
To Lock the Steering : To lock the steering,
turn the handle bar to the left or right. Push
the key inside & turn toward ‘LOCK’ position.
Match the lock position & turn key to ‘LOCK
position. Lock the steering & remove the key.
To Unlock the Steering : To unlock steering,
insert the key in steering cum ignition lock &
turn it clockwise to “OFF” or “ON” position.
Key : A common key is used for ‘Steering
cum Ignition lock’, ‘Fuel tank cap’ & ‘Side
cover RH lock’.

Fuel Tank Cap
Fuel Tap
Fuel Tap
Fuel tap lever has following positions.
ON : When fuel level is above
reserve position.
RES : When fuel level is below
reserve position.
OFF : When fuel supply is to be
cut off.
Petrol Tank Cap & Fuel Tap
8
Fuel Tank Cap
• To open the fuel tank cap, Insert the key in
the lock and turn it clockwise and lift fuel
tank cap.
• ‘Fuel Tank Cap’ is locked when pushed/
pressed back into the place.
Precaution :
• Don’t attach metallic ‘Key chain’ as it may
damage paint of petrol tank cover.
• Don’t put PVC/Rexin cover on petrol tank.
Note : In case petrol spills on to tank, ensure that
tank is cleaned with a clean, dry cloth
immediately.

1
3
7
4
2
Fuel Level Indications
Fuel reserve level
5
6
9
8
10
Speedometer Details
9
1. Odometer : It shows the total distance that the vehicle has
been ridden.
2. Speedometer : The speedometer shows the speed of the
vehicle.
3. Tachometer : It shows the engine speed in RPM.
4. Trip Meter : Trip meter shows the distance traveled since it
was last reset to zero .
5. Turn Signal Indicator(LH & RH) : When Turn signal
switch is turned to Left or Right, Turn pilot indicator - LH or
RH will flash.
6. Hi Beam Indicator : When Headlight is ‘ON’ & Hi beam is
selected with engine running, Hi beam indicator will be lit.
7. Fuel Level Indicator : Shows available fuel in fuel tank.
Fuel Reserve- last 2 bars blinks continuously.
-if level drops further, last bar blinks at faster rate.
8. Neutral Indicator : It illuminates when the transmission
is in Neutral and Ignition switch ‘ON’.
9. Low Battery Indicator : It gets ‘ON’ when Ignition
switch in ‘ON’. Once engine is started,it goes ‘OFF’. If
it glows during running, this means low battery or
malfunctioning in charging system.
10. Trip Meter Reset Button : Press the reset button
for more than 3 sec. to reset Trip Meter reading to
‘zero’.

D
D. Pass Switch : Press switch to flash the head
light.It is used to give signal to vehicles
coming from opposite side while overtaking.
A. Dipper Switch : When headlight is ON,
High or Low beam can be selected with
the dipper switch.
: High Beam : Low beam
B. Turn Signal Switch : When the turn signal
switch is turned to Left ( ) or Right ( )
the corresponding turn signals flash on
and off. To stop turn signal flashing push the
switch in & release.
C. Horn Switch : Press horn switch for sounding
horn.
Hi/Low beam Headlamp Effect of
Switch Status Pass Switch
Low beam Low beam ‘ON’ Hi beam ‘ON’
Hi beam Hi beam ‘ON’ No change
Any OFF Hi beam ‘ON’
A
B
C
Control Switch - LH
10

E. Starter Button : It operates the electric starter
when clutch lever is depressed with transmission
in any gear. It is recommended to start engine
with transmission in neutral.
F. Light Switch : It has 2 positions. When igntion
switch is ‘ON’, lighting system will work as per
given table.
Day Running Light Feature:
• Day Running light is provided inside the
headlamp.
• Day Running light gets ON
(High intensity)
when ignition switch is turned to ON position.
• After headlight is turned to ON position,
intensity of DRL LED’s will get reduced.
: Taillamp will get ON & DRL ON .
(High Intensity)
: Head lamp, Tail lamp, Number plate
lamp, Speedometer illumination will get
ON & DRL remains ON (Low intensity)
F
E
Igntion
Switch
ON
ON
DRL
ON High Intensity
ON Low Intensity
Light
Switch
OFF
ON
Head
Light
OFF
ON
Day Time
Running Light
(DRL)
Note: The inside of the lamp lens might fog up after
using the motorcycle in rain or after washing. Fog inside
the lamp lens will disappear gradually by switching on
the lamp while driving the motorcycle. The amount of
time it takes for the fog to disperse depends on the
humidity of the ambient air. Fog in non functional areas
other than reflector does not affect the lamp performance.
Control Switch - RH
11

Fitment of Side Cover LH
• Match the Lug provided on rear side (C) of
‘Side Cover’ with the hole located on
chassis & press ‘Side Cover’.
• Match Lug provided on front side (B) of
‘Side Cover’ with hole provided on ‘Fuel
Tank’ and press ‘Side Cover’ inside.
• Match the ‘Side Cover’ properly with
bracket provided on ‘Chassis’ & rotate the
key in anticlockwise direction to lock it.
Removal of Side Cover LH
• Insert the key into the cover lock (A) and
turn the key clockwise.
• Hold the cover with both hands and pull
front side (B) first & rear side (C) later.
Take out ‘Side cover’.
CAUTION : Remove cover as described
above, otherwise cover lugs may break.
A
BC
Removal & Fitment of Side Cover
12

Fitment of Side Cover RH
• Match rear side (C) of ‘Side Cover’ lug with
hole located on air filter & press the cover.
• Match the Lug provided on front side (B) of
‘Side Cover’ with hole provided on ‘Fuel
Tank’ & press ‘Side Cover’ inside.
• Match ‘Side Cover’ properly with bracket
provided on ‘Chassis’ & fix it with Screw (A).
CAUTION : Fit cover as described
above to ensure proper fitment.
A
B
C
Removal of Side Cover RH
• Remove the screw (A) given on ‘Side
Cover’.
• Hold the cover with both hands and pull
front side (B) first & rear side (C) later.
Take out ‘Side cover’.
CAUTION : Remove cover as described
above, otherwise cover lugs may break.
Removal & Fitment of Side Cover
13

Removal of Seat
• Remove ‘Side Cover’ LH.
• Pull the ‘Seat Release Cable’ (A) to release
seat lock. Keeping cable pulled, lift the
seat from rear end and slide it towards tail
lamp to remove seat assembly.
Fitment of Seat
• Match & insert the bracket ('1' of Fig. 'B')
of seat with slot ('2' of Fig. 'B') provided
below fuel tank rear mounting on chassis.
• Push seat towards fuel tank and align lock
rod ('3’ of Fig. ‘C') & seat lock ('4' of Fig.
‘C'). Then press the rear portion of seat
from top to lock the seat.
Fig. CA : Seat Release Cable Fig. B
2
1
A
3
4
Removal & Fitment of Seat
14

Tool Kit Location
Make of Battery may differ from vehicle to vehicle
Tool Kit Location
• It is located below the seat on rear
mudguard.
• A rubber strap is provided to hold tool kit.
CAUTION : Always fit rubber strap to hold
the tool kit securely.
Loose tool kit would cause rattling noise.
Battery
• It is located inside the ‘Side Cover’ LH.
• Always maintain electrolyte level in each
cell between Max. & Min. level marks.
CAUTION : Do not drive/run vehicle in
battery disconnected condition. It may lead
to damage of electronic components.
CAUTION : Do not keep head lamp ‘ON’
without the engine running.
Battery & Tool Kit
15

How to Ride Your Bike
16
• Keep throttle completely closed, press starter
button “ ” / apply kick to start engine.
• Release starter button / kick lever as soon as
engine starts.
Note : Do not let the engine idle longer than 3 minutes
otherwise it will overheat.
Caution : Do not operate the starter
continuously for more than 5 seconds otherwise
battery would get discharged. Wait 15 sec.
between each operation of the starter which will
facilitate battery to recover.
Note :
1. The motorcycle is equipped with a
clutch switch. The engine can be started in any
gear if the clutch lever is pressed.
2. Before starting the engine, with ignition key in
off condition, press the clutch lever & operate
kick starter lever all the way down for 5-6
times. Then release the clutch lever.
This practice ensures lubrication of clutch
components for their longer life and prevents
jerky gear shifting.
3. Do not start vehicle without battery
(battery disconnected.)
Starting The Engine :
• Turn the fuel tap knob to ‘ ’ or ‘ ’ position.
• Turn ignition switch key to ‘ ’ position.
• Confirm that transmission is in neutral (must for
Kick start)/press the clutch lever if transmission
is in gear.
• If the engine is cold or when starting for first time
use choke ( ) for quick starting.
Choke
Lever
OFF
ON

th th
From 5 to 4 Gear
Gear Shifting
th rd
From 4 to 3 Gear
rd nd
From 3 to 2 Gear
nd st
From 2 to 1 Gear
-- 45 km/h
Discover 110 Discover 125
24~30 km/h 35 km/h
18~23 km/h 25 km/h
13~16 km/h 15 km/h
Braking :
• Close the throttle completely, leaving the
clutch engaged (except where shifting
gears) so that the engine braking will help
slow down the motorcycle.
• Shift down one gear at a time so that you are
in Neutral when you come to complete stop.
• When stopping, always apply both brakes
at the same time. De-clutch as necessary
to avoid engine stalling.
Warning : When shifting down to lower gear,
do not shift at such high speed that engine
rpm jumps excessively. This may cause engine
damage, and rear wheel may skid. Downshifting
should be done at recommended speeds as
shown in table.
Moving Off :
• Check that Center/Side stand is up.
• Depress the clutch lever.
st
• Shift into 1 gear.
• Open the throttle and release the clutch
lever slowly and simultaneously.
• As the clutch starts to engage, open the
throttle a little more, giving the engine just
enough rpm to keep it from stalling.
Gear shifting
pattern -
All Up-
Discover 110
Shifting Gears :
• Close throttle & depress the clutch.
• Shift into next higher or lower gear.
• Open the throttle and release the clutch
lever slowly and simultaneously.
4
3
2
1
N
Gear shifting
pattern -
1 Down 4 Up
-Discover 125
4
3
5
2
N
1
Recommended Speed for Shifting Down
Note:
For maximum life of engine, never accelerate
harshly when engine is cold.
How to Ride Your Bike
17

• Never jam the brakes, or it will cause the
tyres to skid. When cornering, use brakes
judiciously and do not de-clutch. Reduce
your speed before you get into the corner.
For emergency braking, disregard
downshifting, and concentrate on applying
brakes as hard as possible without
skidding.
Stopping the Vehicle :
• Close the throttle completely.
• Shift the transmission into neutral.
• Bring the vehicle to complete stop.
• Turn the ignition switch off.
Parking the Vehicle :
• Support the motorcycle on a firm level
surface with the center or side stand.
• Lock the steering.
CAUTION : Do not park on a soft or
steeply inclined surface or the motorcycle
may fall over.
Kms 1st 2nd 3rd 4th
0 - 1000 15 25 30 40
1000 - 2000 20 30 40 45
Kms 1st 2nd 3rd 4th 5th
0 - 1000 14 22 30 37 44
1000 - 2000 18 28 38 46 55
Proper running-in is important for better
life and trouble free performance of the
vehicle.
• During first 2000 kms running-in period do
not exceed following speed limits.
• Always keep the speed below the limits
mentioned in the table.
• Do not race the engine excessively.
• Do not start moving or race the engine
immediately after starting. Run the engine
for a minute at idle speed to give the oil a
chance to workup into the engine.
Running IN
Discover 110
Discover 125
How to Ride Your Bike
18

Ensure following maintenance points to get
optimum fuel efficiency from your bike.
Optimum Shifting Speeds for best mileage
Gear
Discover 110 Discover 125
1st gear 0 km/h 0 km/h
2nd gear 16 ~ 19 km/h 14 ~ 17 km/h
3rd gear 28 ~ 34 km/h 22 ~ 25 km/h
4th gear 40 ~ 48 km/h 31 ~ 34 km/h
5th gear Not applicable 38 ~ 42 km/h
How to Ride Your Bike
19
Fuel Saving Tips :
A well maintained vehicle and good riding can
contribute a lot to the saving of petrol. Following are
a few simple fuel saving tips.
Good Riding Habits :
• Ride smoothly and steadily at an optimum driving
speed of 40 to 50 Km/hr
• Avoid harsh braking.
• Change the gear judiciously according to the
speed and load requirement.
• Don’t overload the vehicle above the specified
payload.
• Use the accelerator judiciously.
• Cut off the engine if you want to stop for more
than two minutes.
How to check mileage (Fuel efficiency)
Best way to calculate mileage is by following the full
tank to full tank method.
• Fill fuel in the tank till the bottom of the filling
spout.
• Run the vehicle for 100 kms.
• Fill the fuel in tank, again till the bottom of filling
spout at the same fuel station and fuel dispenser.
• Divide kilometer run / fuel quantity filled.
Fuel Check fuel lines & connections for
leakage.
Spark Plug Inspect and clean spark plugs.
Adjust electrode gap.
Air Filter Clean the air filter element
periodically.
Engine Oil Check level daily. Always use
recommended grade and quantity.
Brakes Ensure that the brakes are not
dragging / binding.
Clutch Ensure correct clutch lever free
play.
Tyre Air Always maintain recommended
Pressure tyre pressure in cold.
Carburettor Periodic adjustment of carburettor.
for idling speed & CO %.